Pulp molding and reforming



June 12, 1945. I M, P. CHAPLIN 2,377,864

PULP MOLDING AND REFORMING Filed Feb. 8, 1941 4 Sheets-Shegt 1 a Amiga?? June 12,.1945. M. P. CHAPLIN PULP MOLDING AND REFORMING Filed Feb. 8, 1941 4 Sheets-Sheet 3 NVENTOR r W 5 June 12,1945. p, CHAPUN 2,377,864 v PULP MOLDING- AND REFORMING Filed Feb. 8, 1941 4 Sheets-Sheet 4 Z Invenfor,

Patented June 12, 1945 PULP MOLDING AND REFORMING Merle P. Chaplin, South Portland, Maine, as-

signor to Chaplin Corporation, South Portland, Maine, a corporation of Maine Application February 8, 1941, Serial No. 378,078

20 Claims.

Pulp molding processes which employ open molds or dies are ordinarily limited to the production of articles having a substantially uniform thickness over the entire die surface. Some thickening may be secured by utilizing any excess pulp which may lodge in deep sections of the mold or in corners adjacent to the molding die ring.

Such thickening is. however, more or less uncontrolled, its operation variable and limited in amount. Frequently, this thickening cannot be secured in a proper location to satisfy all conditions or to adequately provide reinforced sections on certain products.

Reinforcing may be accomplished by employing auxiliary molds and consolidating together sections molded on different dies. This, however, requires extra die equipment.

It is the purpose of this invention to provide means for molding on a single die, a molded article of pulp of substantially uniform thickness with auxiliary means for reforming certain sections of this article to provide reinforcing of certain parts of the finished article.

In the drawings:

Fig. 1. .Primary molding die on which the initial molded article is formed.

Fig. 2. The molded article of pulp on the primary molding die being compressed by the reforming die.

Fig. 3. A reforming die with a. portion of the molded article partially reformed.

Fig. 4. The reforming dieand a pressing die effecting additional reforming of a portion of the molded article.

Fig. 5. The molded article held between the pressing die and a drying die effecting final reformation of a portion of the article and the drying of all of the article.

Fig. 6. Section through pressing and drying dies on line 6-6 of Fig. 5.

Figs. 7-8-9-10. These illustrate modifications in shape of the reinforced portion.

Fig. 11. One type of article which may be produced by the process herein described.

Figs. 12-22 show a modified form of the invention wherein Fig. 12 is a fragmental radial section through this modified form of the invention illustrating a pair of forming dies adapted to cooperate with one another to superimpose independently formed article sections. This figure shows two forming dies separated. I

the dies in position to superimpose one pre-formed section upon the other.

Fig. 14 is a similar section showing the product of the operations illustrated in Figs 12 and 13.

Fig. 15 is a fragmental radial section showing the transfer of the product of Fig. 14 from one of the forming dies to a primary shaping die.

Figs. 16-17-18 are like views showing the primary shaping die cooperating with the secondary shaping die in different steps of the method.

Fig. 19 shows the product of illustrated in Figures 16-17-18.

Figs. 20-21-22 are similar sections showing progressive steps of final compressing and finishing of the article. These figures are on a larger scale in the interest of clearness.

In Figs. 23-33 I have illustrated still another form of the present invention wherein Figs. 23-24-25 correspond to the showing of Figs. 12-13-14.

Figs. 26-27-28-259 correspond to the showing of Figs 15-16-17-18 with the structure modified to incorporate limiting stops which bring about a modified form of operation constituting a modified method.

Fig. 30 is a fragmental section of the product of the method steps shown in Figures 26-27-28-29.

Figs. 31-32-33 show consecutive die positions in compressing and finishing the product shown in Fig. 30.

The pulp article or wet molded product is initially formed on a molding die 5, by depositing on a wire mesh covering 2, over the surface of this die, a layer of pulp 3, by means of suction, applied to the interior t, while the die surface is immersed in a mixture of fibres and liquid. The

' die I, has perforations 5, therethrough and the Fig. 13 is a View similar to Fig. 12, but showing chamber l behind these perforations is normally closed by a cover or die carrier (not shown) to which connection is made to the source of suction. The wire mesh die covering 2 is held in place by a retaining ring 6 having a recess 1 to centralize reshaping ring 8 which is vertically slidable on surface ll of a centrally disposed portion Ill of die 9. Springs I3 normallytend to move ring 8 to bring its flange 8a into engagement with flange Ma of another ring member It (see Fig. 3).

After the molded article 3 has been formed on the molding die I, the pressing die 9 is used to compress the layer of pulp fibre on the die I and p to remove it therefrom. As the die 9 is brought into cooperative position with the die l and the pulp layer thereon the ring 8 on the pressing die first encounters the ring 6 on the forming die,

the operations and particularly, the recessed portion 1 and is guided into place by the bevel section thereon. After the outer surface l5 of the ring 8 has become seated on the surface l8 of ring 8 continued motion of the die 9 towards the die I, compresses the springs l3, forcing the ring 8 downwardly over a portion of the die 8, and particularly, over the peripheral surface until the internal surface of the section ID of die 8 encounters the pulp article 3 on die I, compressing the article between these two dies. The upper marginal flange 3a of the molded article 3 is not compressed during this operation and continues to project laterally outward as it was initially formed,

After the article has been thus compressed, the dies are separated and the molded article 3, is removed from die I, and retained on die 9, as indicated in Fig. 3.

However, as the dies and 9 separate the spring i3 holds the ring 8 in contact with ring 8. insuring that the dies separate evenly and without misalinement, and as the ring 8 moves outwardly relative to die 9 the section 3-a is bent inwardly by the bevel section l2 on ring 8, as is indicated in Fig. 3. The article is retained on the inner surface of section III of die 9, by means-of suction applied through holes il in this die, suction being applied to chamber I8 behind the die surface I, which chamber is formed by a cover plate or die carrier (not shown).

For effecting further reshaping of the edge 3-a of the pulp article 3, a pressing die I9 is brought in contact with the pulp article 3 held by die 9, as is indicated in Fig. 4. This die I9 is guided into proper position with die- 9 by means of the bevel portion l2 on the ring 8, the springs l3 holding the ring 8 in its outward position as shown in Figs; 3 and 4. It will thus be seen that this bevel portion l2 on ring 8 has a dual purpose. First, to effect partial reformation of a portion of the pulp article as is indicated in Fig. 3, and second, to guide pressing die I9 into proper position to effect a further reshaping of a portion of the molded article at 28 and to assist in such reformation. The molded article 3 is then discharged or blown from die 9, by application of air pressure through holes effecting the transfer of the molded article from die 9 to die i9. Immediately after being transferred to die l9 it is compressed by a drying die 2 I, which not only serves to compress the article against die i9, but also cooperates therewith to effect a final reforming f the edge portion 3-a of the article as is indicated in Fig. 5.

The drying operation performed in Fig. isnot included, per se, as a part of this invention and reference is made to copending abandoned application U. S. Serial No. 135,033, which covers more in detail, this operation and Fig. 5 is simply illustrative of the final operation on the article and more particularly, the completion .of the reforming of edge portion 3-a.

It is further understood that the operation illustrated in Fig. 5 may be augmented by other operations and procedures performed on the pulp article prior to the final operation which operations and procedures are covered by copending application above mentioned. However, as the final stage of the reforming operation is included in the drying operation, the function of dies |9 and 2| will be described.

The die 2| is provided with an inner section having perforations 22 therein. These perforations may extend completely through the die or the inner surface may be provided with grooves or slots 23 through which vapor may escape. Behind the die 2| is a chamber 24 with a pipe 28, through which vapor from the article 3 may be drawn away. Surrounding the chamber 24 is a wall 21 on the outer side of which is an outer wall 28 enclosing a chamber 28, to which chamber may be supplied steam or other heating medium through pipe 29.

The heating medium introduced in chamber-28 heats the inner wall 21 of this chamber, heat from this wall being conducted to the die wall 2| by means of connecting ribs 38. These ribs serve to keep the inner wall 2| at a temperature which will vaporize the water or other liquid contained in the article 3 compressed between the die 2| and the die l9.

If desired, the die I9 may be heated by providing a cover plate 32 inclosing a chamber 3| on the interior of said die to which chamber steam or other heating means may be supplied through pipe 33. Providing heat to this die l9 will serve to hasten or speed up the removal of the water or other liquid from the article 3.

It will thus be seen that means has been provided through a specially constructed reshaping die and mechanism illustrated in Figs. 2 and 3 for reshaping a certain portion of the molded pulp article which portion may be finished in any desired shape as illustrated in Figs. '7, 8, 9 and 10.

It will also be observed that I have provided means for utilizing ordinary pulp molding methods in the forming of the original wet molded artcle or layer of pulp, which article or layer is thereafter immediately removed therefrom and subjected to the reshaping and finishing operations heretofore described, thereby releasing the molding die for the molding of a second or subsequent article.

Attempts to reshape the article or a portion thereof, while still retained on the forming die complicates the molding procedure and tends to injure the wire covering of the molding die or other foraminous surface thereon, as well as to plug the perforations in the molding die at this point and defeat the very purpose intended: namely that of providing surplus or extra pulp fibre materials at the point where reinforcing of the finished article is desired.

By providing auxiliary reshaping dies having smooth metal surfaces properly beveled and shaped, I am able to reform the surplus portion of the molded fibrous article provided by the molding die while the article is still moist and the fibres loosely interlocked, into a new shape, compacting the fibres into this new shape in a dense, uniform structure.

At no time, during the reshaping operation, are the fibres of the surplus rim section stretched or distorted from their original interlocked condition but rather, are folded over and reshaped on themselves, effecting the maximum utility of fibre strength for the particular section of the article where it is most needed.

There is illustratedin Fig. '7, a reinforced edge substantially square in outline. To produce this shape, die l9 would, at point 35, have a square or substantially square section instead of the rounded section shown in Fig. 5 and the upper margin of thegcavity of die 2| would have an opposing sq'uare section instead of the rounded section shown in this latter figure.

The edge illustrated in Fig. 8 and in Fig. 9 is similar to that shown in Fig. 5. In Fig. 9 the reinforcing is carried down farther into the body of the sheet and is oval rather than round, as is shown in Fig. 8.

While the article taken for purposes of illustration is a relatively deep dish or cup, as shown in Fig. 11, the reforming operation herein described may be equally useful in providing a reinforced and finished edge or rim on a plate or dish such as is illustrated in Fig. 10.

In Fig. 11, there is shown a perspective view of a finished article, which may be produced by the methods heretofore described. The reinforced rim section is shown at 3-a. this corresponding to the section illustrated in Figs. 5 and 8. If desired, the surface of the article may be left in a, condition, prior to its being placed in die 21, so that small ribbed orridged sections may be pressed into slots 23 in die 2|, as shown in Fig. 6, giving a distinctive and finished appearance to the exterior of the article. In case of a cup or similar article, these slightly ribbed or ridged sec- .tions will enable the cup to be more readily held in the hand than would bethe case if the outer surface were entirely smooth.

However, if the marks or ridged sections left by the slots 23 in die 2| are not desired, either the surface of the sheet, prior to its application to die 2|, may be treated, as described in my copending application previously mentioned, or the article may be withdrawn slightly from the surface of die 2i, by a slight outward movement of die i9 during the drying operations, the die i9 and the article being rotated slightly to bring the section opposite the grooves into position to be smoothed out by the smooth surface of the die 2i, between these grooves. By properly arranging the time for moving the article and turning the same, relative to the drying operation and the hardening of. the surface of the article adjacent to die 2!, the exterior surface of the article may be finished entirely smooth,'

or substantially flush or certain portions of the ridge structure or markings or indentations there of may be left in the surface eifecting a distinctive and attractive appearance but with little or no projecting parts or portions of the article beyond its exterior surface.

The necessary mechanism for moving the various dies into or out of cooperative relation has intentionally been omitted, as well as the means for applying pressure and suction to the chambers back of the various dies. Also, the mechanism for rotating the die it) where it is desirable to eliminate the groove marks of the drying die, or to impart a distinctive pattern to the article, has not been shown. It is understood however, that any suitable mechanism may be employed to first separate dies i9 and ill by a slight amount, and while separated one of the dies is rotated about its axis an amount approximating one-half space between grooves 22 and 23 in die 2!. The projection formed on the article of the slots is ironed out or pressed back into the article surface when the dies are again closed. It is, of course, understood that this operation is performed early in the drying cycle, and before the ridges or ribs formed on the article as well as the article itself have been thoroughly set. This is necessary as both ribs and articles are of substantially the same density and if the ribs are to be eliminated, the articles must still hold a substantial amount of moisture.

Figs. 12-22 illustrated a modified form of the invention as hereinafter more fully described. The showing in these figures may be utilized in practice to produce either a single or a multi sec tion article.

By single section article is meant a finished article formed initially from a single section of material upon an appropriate formingdie. By a multi section article is meant an article wherein a plurality of independently formed sections are superimposed upon one another and thereafter acted upon in accordance with the present invention to produce in effect a substantially integral end product. The advantage .of the socalled multi section article is that it permits the use of pulp of different grades to form different portions of the thickness of the article. For example, in the manufacture of a plate or the like, the articlemay be made with a lining of high grade pulp in order to give the desired appearance and finish, while the remainder of the thickness of the plate may be made from a less expensive material adapted to impart to the article the desired strength and rigidity. However, this arrangement may be reversed or modiin the manufacture of some articles. It is also within the purview of the invention to provide sections of the same or different materials on opposite sides of a section of a still different material.

Referring first to Figs. 12 and 13, 3'7 and 38 are two independent molding or forming dies of any appropriate shape and construction, but, in any event, so constituted that they are adapted to form upon their contoured surfaces a section of wet pulp from a liquid-pulp mixture. As shown in these figures said dies are of the suction type with a suction chamber 39 in the die 31! and a suction chamber to in the die 33. Suction passages M lead from the suction charmbers to the contoured surfaces of the dies and, if desired, said contoured surfaces of the dies may be covered by the conventional screen. In practice these dies 3! and 38 are charged with pulp in any appropriate manner as by dipping them into a liquid-pulp mixture and exhausting water through the dies to deposit a pulp article on to each die. These operations are carried out independently although in practice the operation may be simultaneous. In any event, the desideratum is to obtain a wet formed pulp section it on the die 31! and a wet formed pulp section it on the forming die 38.

After these pulp sections have been formed on the respective dies, the dies are brought into substantial alinement, as shown in Fig. 12, and

thereafter they are axially moved toward one another so as to deposit the section M on to the section 63 as shown in Fig. 13.

During this operation it is desirable that the sections be not compressed, but that the operation be merely one of superimposition. In order to accomplish this result and also to insure proper registration, the die3l is provided at its outer margin with a depending flange M adapted to seat upon an abutment or stop if) on the die 38, the parts being so proportioned that these parts will contact with one another before pressure is exerted upon the pulp sections.

During this operation suction is preferably maintained on both of the dies, so as to hold the sections in place thereon. However, after the sections are superimposed as stated, suction is retained upon the die 38 while the suction is broken on the die 31, and, if desired, compressed air is introduced into the chamber 39 so as to remove the pulp section 42 from the die 31, so

that when the die 31 is lifted, the superimposed pulp sections will be left on the die 38.

The product of the foregoing operations is shown in Fig. 14. Here the article sections are shown as superimposed upon one another in wet uncompressed condition. This view also shows the marginal portion of the pulp section 42 extending beyond the outer periphery of the pulp section 43. This need not-necessarily be so in accordance with this invention, but I prefer to make them this way, so that in the finished article, the outer edge of the pulp section 43 will be enclosed within the material of the section 42, this being particularly so in cases where the section 42 is made from a higher grade of pulp. The difference in size of the respective sections 42 and 43 i provided for by appropriate construction of the dies 31 and 38 as will be well understood.

After the forming die 31 has been withdrawn from the die 38, as described, the two superimposed pulp sections will be left in the die 38. This latter die is thereupon brought into cooperative relation with a primary shaping die shown as the upper die in Fig. 15 and indicated generally by the reference character 46.

This primary shaping die is shown as comprising a die body 41 having a foraminous contoured face 48. The die body is embraced by a shaping ring 49 exteriorly flanged at its upper end, as indicated at 80, to operate within a limiting ring The die body is mounted on any suitable support or apparatus whereby it may be bodily manipulated while the axial movement of the shaping ring is adapted to be independently controlled. This control may be accomplished in various ways and its movements may, in some cases, be spring actuated, as indicated in Figs. 2-3-4- of the drawings. However, I have found it possible to positively control the operations 40 of this ring in a manner to obtain results not heretofore accomplished in this art. Various forms of mechanical means may be utilized for this purpose, but in Fig. 15 I have shown/a simple form which is thoroughly practical for production purposes. Here the ring is shown as provided with a cylindrical lug 52, it being understood that a plurality of these lugs are positioned about the periphery of the ring to extend radially outward therefrom and with each pin is associated a clevis 53 which constitutes the operating means therefor. These clevlses are connected by suitable mechanism to any appropriate prime mover by which the ring may be moved axially of the die at predetermined intervals and in timed relation to the operations of the die.

When the forming die 38 with the sections 42 and 43 thereon is brought into axial alinement with the primary shaping die 46, these dies are brought together so that the bodies of the superimposed sections are compressed between the contoured surfaces of these dies as indicated in Fig. 15. It will be noted, however, that the marginal portions of both sections which constitute the edge portion of the assembly extend beyond the compression surface of the upper die 4! so that, as the bodies of the sections are compressed together, the said edge portions of the article are not compressed, but are left in the original wet formed condition. During this compressing step of the method the shaping ring 49 is held in elevated position, but its. lower end overlaps the outer periphery of the lower die so as to guide and center these dies prior to contact of the shaping die with the article.

After the parts have been brought into the position shown in Fig. 15 and the body of the article compressed as stated, suction is applied to the primary shaping die, while suction in the forming die 38 is discontinued and, if desired, compressed air admitted to insure that when the dies are separated, the sections 42 and 43 will remain on the die 46. The die 38 is now removed and a secondary shaping die 54 is brought into cooperation with the primary shaping die 46 as shown in Fig. 16. These two dies are forced firmly together on the intermediate article as shown, preferably further compressing the portion of the body of the article interposed between them.

While the article is being held firmly between these dies as shown, the shaping ring 48 is lowered by its operating clevlses 53 thereby causing a tapered portion 55 in the bore of this ring to act upon the still wet uncompressed edge portion of the article, as shown in Fig. 16. Inasmuch as the section 42 projects beyond the section 43, the projecting portion of the former section will be acted upon first and deflected downwardly over the outer edge of the section 43, as clearly shown in this figure. As the operation progresses, however, the more constricted part of the tapered portion 55 will shape the edge portions of both sections 42 and 43 simultaneously until the tapered portion has passed beyond contact with these edge portions to leave them in the condition shown in Fig, 17. This having been accomplished, said edge portions are next acted upon by a shaping ring 56 which slidably embraces the secondary shaping die 54 and is of a size to be received within the cylindrical bore of the upper shaping ring 49. The ring 58 is adapted to be positively operated in timed sequence with the operations of the ring 49. This ring 86 may be positively operated as is the case with the ring 49 by any suitable mechanism, but, for the purpose of illustration, I have shown the ring 56 as operated in substantially the same manner as the ring 49. In this instance the ring 56 has a plurality of pins 61 with operating clevlses 58. The timing is such that after the ring 49 .has been lowered into the position of Fig. 17, while the ring 56 is in a lowered position, this ring 55 is now elevated and compresses the previously uncompressed and still wet edge portion of the article to substantially the same density as the remainder of the body and simultaneously shapes the same as shown in Fig. 18, wherein it is in approximately its final form. If desirable, drainage openings may be provided to permit of the exit of any water which may be expressed during this operation. At the conclusion of the step described in connection with Fig. 18, the product article is as shown in Fig. 19.

In practice the compression to which the body of the article and the edge portion thereof has been already subjected as described may be sufficient for the purposes intended in which case the product of Fig. 19 may be dried in any suitable manner and thus prepared for the market. However, in the preferred form of this invention, I prefer to subject the article of Fig. 19 to a further, and final die finishing and drying step.

The article of Fig. 19, therefore, after being removed from the dies 49 and 54 of Fig. 18, is brought into cooperation with finishing dies 89 and 88 which are preferably heated dies and Y which dies are preferably provided with any apresults from heating the still moist article between heated dies.

These dies 59 and 60 are shown as interfitting v and self centering. As the die 59 approaches the die 60, the outer periphery of the die 59 telescopes into an upstanding peripheral wall 52 on the die 50 which causes the dies to be centered and guided into proper registration. As the die 59 nears its seat, a depending flange 63 on said die enters into an annular recess 64 in the die 60 with the inner face 65 of the flange having a very close clearance with the surface 66 of the die 60. The surface 65 is so proportioned, however, that when the article is resting uponthe contoured surface of the die 60, the surface 65 will clear the outer periphery of the article as the die 59 moves downwardly to its seat, thereby avoiding any possibility of damage to the still moist edge portion of the, article or any possibility of carrying any portion thereof into the recess 64. Thu by the time the dies come into the position shown in Fig.

21 and before they actually exert any pressure upon the article, the compression space between these dies is completely closed. The dies continue to move together until they reach the positions shown in Fig. 22 and in the interim force and further compress the article into its final form while the heat of the dies produces the desired finish.

It is to be noted that the article contacting faces of either or both of the dies 59 and 60 of Figs. -21-22 and the corresponding dies of Figs. 31-32-33 may be provided with vapor escape grooves or ducts like the grooves 23 of Figs. 5-6. These vapor escape ducts, which are formed in the face of the die which directly contacts the article without any intervening mesh or the like, are so located in the face of the die as to extend in the direction of the draw of such die. Ordinarily I employ these vapor escape grooves on y in the face of one die, although they may be provided in both dies or, if desired, in parts of surfaces of either or both dies.

When I compress the still moist article against a surface of a die provided with such vapor escape ducts, I apply sufilcient pressure to cause small portions of the damp blank which are juxtaposed with the ducts to be squeezed or proiected into these grooves and, since either or both of the dies are of the heated variety. the water remaining in the article will be vaporized and led off throu h the vapor channels or ducts, so that the article is dried and the fibres of the article are fixed and set in this condition permanently. Consequently. the article. when removed from the dies in this dried and set condition. will have (if these vapor channels are incor orated in the die) an external ribbed formation or pattern, generally indicated in Fig. 11.

These external ribs on the article may be made of any des red width. shape or pattern without departing from this invention. However, in practice, I make them quite narrow with respect to the spacing between them for the reason presently explained. I have found that the ribs should. for the best results, be made so narrow that, when eliminate lines or weakness in the inner strata of the article.

With this mode of operation, the initial drying die pressure on the article produces the ribbed pattern thereon and the dies, being heated, immediately thereafter set and fix the fibres in and adjacent to the ducts, thereby forming a bridge across the duct, enabling heat and pressure to be imparted uniformly thereafter throughout the entire body of the article to complete the drying and finishing operation.

The article is held between the dies as in Fig. 22 until the finishing operation is completed. The dies are then separated and the article removed and may be in condition for the market. It will be understood, however, that further and additional steps may be added, although these are not ordinarily necessary.

In the apparatus and method as described in connection with Figs. 12-22, two independently formed pulp sections are initially prepared and assembled. The invention, however. may be carried out by dispensing with one of these sections, in the event that one grade of pulp only is desired. The invention is to be understood as broad enough to cover this procedure, as well as the formation and finishing of an article made up from more than two wet-formed sections superimposed as described.

In all of the methods and apparatus which have hereinbefore been described, the body of the article is compressed, while the edge portion of the article remains in original wet formed state and this edge portion is thereafter or subsequently shaped and pressed into its final form either by one or a plurality of steps as the case may be. In other words, one portion of a wet formed or molded article is compressed, while another portion of the same article in thewet formed state is subsequently and while still wet in turn shaped and compressed into its .desired final shape.

According to the method already described herein, the body of the article is first compressed and the edge portion thereafter shaped and compressed. It is within the purview of this invention, however, to reverse these operations, 1. e., to shape andcompress the edge portion of the article while the body of the article remains in its initial wet formed state and, thereafter, and as a subsequent step, compress this still wet body into substantially its final form.

The apparatus and method whereby this latter I procedure is accomplished are illustrated in Figs.

The method of these latter figures commences identically with the method of Figs. 12-22. Thus pressure is applied by the die to the parts of the acros the relatively small spacing between the zones of applied pressure (i. e., across the duct),

so as to bridge the foundations of the ribs and thus harden and compact the same, and thereby the steps of the method of Figs. 23-24 are identical with those carried out in Figs. 12-13 and yield the product of Fig.25 identical with the product of Fig. ,14. Furthermore the product of Fig. 25 while on the forming die 38 is brought into cooperative relation with a primary shaping die it identical with the primary shaping die of Fig. 15 with two important exceptions. The first is that in Fig. 26 the shaping ring M is provided with an internal sto or abutment El, so placed that it will abut against and seat upon the die 38 before the die 46 can exert pressure upon the formed sections-of the article between these dies. In other words, the ring 419 acts as a positive spacing ring for positively spacing the dies apart in such manner that their contoured surfaces can never come closer to each other than the maximum thickness of the formed article sections. Consequently, when the dies are brought together. as shown in Fig. 26, the formed article remains in its wet formed condition free from compression instead of the body thereof being compressed as in Fig. 15. The second exception to identity is that the limiting ring, which is rigid with the die 48, is provided with a flange having an abutment Bl-a adapted, as hereinafter described, to coact with a stop 54a rigid with the die 54.

After the parts have been brought into the position and condition shown in Fig. 26, the die 38 is removed and the die 46 with the article thereon is brought into cooperative relation with the secondary shaping die 54 as shown in Fig. 27, but here again the dies 46 and 54 are not utilized to compress the body of the article, but are positively spaced apart by engagement of abutment 81-0, with the stop 54-a, so that they do not compress the body of the article in this position at any point during the operations of any of Figs. 27-28 or 29.

It will be noted, however, that theoperations disclosed in Figs. 27-28-29 with respect to the movements of the shaping rings 49 and 58 are the same as described with respect to Figs. 16-17-18 in that the tapered portion 55 of the shaping ring deflects the still wet edge portion through the position of Fig. 27 into the position of Fig. 28 and thereupon the shaping ring 56 is elevated to further shape and compress the still wet edge portion into the form of Fig. 29.

Thus, as the article comes from the die after completion of the method step of Fig. 2'7, it is the article of Fig. 30 wherein the thickened reinforcing edge portion has been compression shaped into approximately final shape, while the remainder of the article, i. e., the body thereof, is in a still wet, original, uncompressed, molded condition.

After the article of Fig. 30 has been produced as stated, it i then introduced between drying and finishing dies, as shown in Figs. 31-32-33 and therein subjected to heat and compression to dry and finish the same, the dies being of the same character as specified in connection with Figs. 20-22.

While I have described my invention with particular regard to the production of an article, such as a cup, plate or dish, it will be readily understood that my invention is capable of producing a wide variety of articles, particularly those where reinforcement is necessary or desirable about a rim or edge which may become broken or bent when the article is used. It is equally obvious that many modifications can be made in the shape of the reinforced section, other than those illustrated herein.

In the foregoing disclosure 1 have shown, particularly in Fig. 11 of the drawings, for the purpose of illustration, a circular article as the product of my dies and methods. This invention is, however, manifestly not limited to a circular article as the article may have a curvilinear, or a polygonal form, or a combination of these forms. Moreover, the so-cailed shaping rings which have been described in connection with diflerent embodiments of the invention have been referred to generally as operating upon the edge or marginal portion of the article throughout its entire extent. However, it is within the present invention to so constitute this ring or these rings or equivalent members, with appropriate modification of the die structure, so that said rings will operate upon all or only on such portion or portions of the marginal edge as it may be desired to reinforce.

' This application is-a continuation-in-part of application, Serial No. 144,439, filed May 24, 1937.

Having thus described my invention what I claim is:

1. In the method of producing a molded pulp article, the steps of forming a contoured article of pulp of substantially uniform thickness on a foraminous forming die, thereafter compressing a portion of said formed article with a second die while the article remains on the forming die, and thereafter reshaping the uncompressed portion of said formed article as it is removed from the forming die.

2. The method of producing a molded pulp article which comprises forming a layer of pulp of substantially uniform thickness on a foraminous forming die, thereafter compressing a portion of the formed article with a second die while the article remains on the forming die, thereafter removing said article from the forming die and simultaneously partiallyreshaping the uncompressed portion of said article, and thereafter compressing said uncompressed portion of the article.

3. The method of producing a molded pulp article which comprises molding on a foraminous forming die from a liquid-pulp mixture a contoured fibrous pulp article of substantially uniform wall thickness, thereafter applying a compression die to a portion only of the contoured surface of the molded article to compress said pulp, thereafter removing the thus molded and compressed article from the forming die and during such removal simultaneously reshaping the uncompressed portion of the article, transferring the article to a finishing die and simultaneously furtherreshaping said molded article, and compressing and finishing the entire article by applying pressure to all portions of the article.

4. The method of producing a. molded pulp article which comprises molding on a foraminous die an article of pulp from a liquid-pulp mixture, compressing said article against a heated die having perforations therein, retaining said article in contact with said die until a part of the liquid contained therein has been evaporated, removing said article from contact with said heated die, changing the relation of said article and said die to bring the portions of the article first over the die perforations over the unperforated die surface, and again compressing the article against said heated die to complete the drying of the article.

5. The method of producing a molded pulp article which comprises molding on a foraminous die an article of pulp from a liquid-pulp mixture. thereafter compressing said article against a heated die having passages for the escape of vapor in its face, retaining said article in contact with said heated die until a part of the liquid contained in the article has been evaporated therefrom, thereafter removing said article from contact with the heated die, changing the relation of the article and the heated die to bring the portions of the article first over said vapor passages into positions over portions of the heated die which are without such passages, and thereupon again compressing the article against said heated die.

6."I'he method of producing a molded pulp article which comprises depositing a wet pulp article of substantially uniform thickness from a liquid-pulp mixture, thereafter shaping and compressing the still wet edge portion of the article to produce a reinforcing edge of increased thick.

ness and compressing portions of the body of the still wet article spaced from one another to provide zon s of compressed decreased thickness with interme late zones of greater thickness merging into the reinforcing edge and drying the article.

7. The method of producing a molded pulp article which comprises depositing a wet article, of pulp of substantially uniform thickness from a liquid-pulp mixture, and shaping and compressing the still wet edge portion of the article to produce a thickened reinforcing edge and compressing the still wet body of the article at areas thereof to form between them raised external ribs merging into the reinforcing edge.

8. The method of producinga molded fibrous pulp article which comprises separately molding from different liquid-pulp mixtures a plurality 4 of wet complementary molded pulp sections, thereafter superimposing said still wet sections in nested relation with respect to one another to provide an article of wet molded, pulp, thereafter compressing a portion of the still wet article while leaving another portion of the article in wet uncompressed state, and thereafter compressing the wet uncompressed portion of the article before it is dry.

9. The method of producing a molded fibrous pulp article which comprises separately molding from different liquid-pulp mixtures a plurality of wet complementary molded pulp sections, at least one of which is larger than another, thereafter superimposing said still wet sections in nested relation with respect to one another with the margin of the larger section projecting beyond the edge of the smaller section to provide an article of wet molded pulp, thereafter shaping the projecting portion of the larger section into a position to enclose the edge of the smaller section and reshaping the margins of both of said sections into a reinforcing edge portion of increased thickness, and thereafter compressing the resulting edge portion of increased thickness and also compressing the body of the article.

10. In an apparatus for molding fibrous pulp articles, a foraminous molding die, a ring member thereon defining the extreme edge of the molding surface of the molding die. said ring member having means thereon for locating a cooperating compressing die, and a compressing die with a ring member thereon cooperating with the ring member on the molding die said ring being movable axially of said compression die to cause compression of the article between said dies and to reshape the marginal edge of the article after compression between said dies.

ll. In an apparatus for molding fibrous pulp articles, an open face die to receive a contoured wet pulp article on itsopen face with the marginal portion of the article projecting beyond the periphery of the die, a shaping ring embracing said die and supported for movement in a direction perpendicular to the open face of the die, shaping: means on said ring to engage with said projecting marginal portion of the article on the die, and means to move said ring to bring said shaping means thereof into engagement with said projecting marginal portion while the article remains on the die, for the purpose of fashioning said marginal portion of the article into a different shape.

12. In an apparatus for molding fibrous pulp articles, an open face die adapted to contact with one face of a contoured wet pulp article with the marginal portion of said article projecting beyond the periphery of the die, a shaping ring embracing said die and supported for movement in a direction perpendicular to the open face of the die, shaping means on said ring to engage with said projecting marginal portion of the article, and means to-move said ring and its associated shaping means into engagement with said projecting portion of the article, for fashioning said marginal portion into a different compressing die cooperative therewith, a ring member on the compressing die movable relative thereto, means on the molding die for retracting said ring member relative to the face of the compressing-die to enable said compressing die to contact with and receive from said molding die an article molded thereon without engagement with said ring, and means to advance said ring relative to the face of said compressing die to engage with and reform a portion of the molded article received by said compressing die.

14. Pulp molding apparatus comprising a foraminous molding die for forming a molded pulp article, a compressing die cooperative with said molding die for applying pressure to the article formed on the molding die, said compressing die having a movable ring member thereon. means to move said ring member to enable said compressing die to enter said molding die and contact with and remove from said molding die the molded pulp article, and means to move said ring member relative to the compressing die and into contact with the article. during removal of the article by said compressing die, to reform a portion of the molded article.

15. An apparatus of the character described comprising; a pairof coaxial dies adapted to engage the opposite faces of a molded pulp article interposed between them with the marginal portion of the article extending beyond the opposing article engaging faces of both dies, a shaping ring embracing one of said dies and movable coaxially thereof to overlap the other die and form therewith a chamber into which the marginal portion of said article is deflected by said shaping ring when said ring ismoved into such chamher-forming position, and a second shaping ring movable coaxially of the dies into said chamber to compress the deflected marginal portion of the article therein.

l6.- An apparatus of the character described comprising; a pair of coaxial dies adapted to engage the opposite faces of a molded pulp article interposed between them with the marginal portion of the article extending beyond the opposing article engaging faces of both dies, a shaping ring embracing one of said dies and movable coaxially thereof to overlap the other die and form therewith a chamber into which the marginal portion of said article is deflected by said shaping ring when said ring is moved into such chamber-forming position, and means for compressing said deflected marginal portion in said chamber.

1'7. The method of producing a molded fibrous in which it was formed, compressing said bent edge portion in the confines of a chamber to form a still wet thickened edge and drying said article.

18. The method oi producing a molded pulp article which comprises: molding an article of pulp from a liquid-pulp mixture, compressing the thus formed article between two dies at least one of which produces projections on said article and also has intervening smooth surfaces, then separating the article from contact with the die which produced said projections, then rotating one of said dies 'so that the projection forming parts of the die are out of register with the projections which were formed thereby on'said article and inregister with said smooth surfaces of the die, and thereupon again compressing the article between the same two dies to at least partially smooth out said projections.

19. The method of producing a molded fibrous article which comprises: forming from a liquid fibrous mixture a wet'fibrous article having an open top receptacle portion surrounded by a marginal edge portion, bending at least a part of said marginal portion of the still wet article in a direction normal to the plane oi. the open top of said receptacle portion, then compressing said bent marginal portion in a confined space to form about said receptacle portion a peripheral flange of greater depth than the thickness of the wall of the receptacle portion and drying the resulting article between pressure dies at least one 01 which is heated.

20. The method of producing a molded fibrous article which comprises: forming from a liquid fibrous mixture a wet fibrous article having an open top receptacle portion surrounded by a marginal edge portion, bending at least apart of said marginal portion of the still wet article in a direction normal to the plane of the open top of said receptacle portion, then compressing said bent marginal portion in a confined space to form about said receptacle portion a peripheral flange of greater depth than the thickness of the wall of the receptacle portion, then compressing the still wet article at areas thereof to form between them raised external ribs merging into said peripheral flange and drying the resulting article.

MERLE P. CHAPLIN. 

